CN115488504B - Laser welding process for realizing continuous regulation and control of effective melting width of laser lap joint junction surface of active heat protection structure - Google Patents
Laser welding process for realizing continuous regulation and control of effective melting width of laser lap joint junction surface of active heat protection structure Download PDFInfo
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Abstract
A laser welding process for realizing continuous regulation and control of effective melting width of laser lap joint surface of active heat protection structure belongs to the field of laser welding manufacture. Aiming at the structural characteristics of dense welding seams and continuous change of the widths of the ribs of the active heat protection component and the service characteristics of different working temperatures of all positions of the component, the effective continuous change of the width of the joint surface in the same welding seam is realized by carrying out combined regulation and control on laser power, welding speed and defocusing amount in the welding process based on the requirements of the widths of the ribs and the working temperatures on the width of the joint surface of the lap welding seam. The welding process can effectively reduce the overall welding heat input and the welding area on the basis that the joint quality meets the high-temperature strength (effective melting width) of the welding line of the component, further greatly reduce the residual stress of the component, reduce the defects of crack tendency, welding deformation, size instability and the like of the welding line, and improve the laser welding manufacturing quality of the active heat protection component.
Description
Technical Field
The invention relates to a laser welding process for continuously regulating and controlling effective melting width of a laser lap joint surface of an active heat protection structure. In the welding process, the effective continuous change of the melting width of the joint surface in the same lap joint weld seam is realized through the combined regulation and control of laser power, welding speed and defocusing amount, and the method is suitable for the laser welding manufacture of the active heat protection component and belongs to the field of laser welding manufacture.
Background
Hypersonic aircrafts are a main trend of modern aircrafts, and are important guarantees for obtaining future military advantages and national defense safety. Engines are well known as core components of aerospace vehicles. When the aircraft flies at a speed greater than Ma5, high-temperature fuel gas in the engine flows at a high speed, so that the heat flux density of the wall surface of the combustion chamber of the engine is as high as 10-20 MW/m 2, and the temperature is as high as 3500K. Therefore, effective thermal protection techniques are necessary measures to ensure long-term stable operation of the engine structure. The technology utilizes the fuel flowing in the flow channel at high speed to cool the structure by manufacturing the active heat protection structure with the precise complex intensive inner flow channel, and simultaneously, the preheating of the fuel is realized, the components are effectively cooled, and the working requirement of long-time high heat load is met.
At present, the welding between the skin and the substrate with dense flow channels is realized by adopting a laser welding process, and the welding has proved to be an effective active heat protection component manufacturing process route. The lap joint is the main joint form of the structure, and the effective width of the joint surface between the skin and the matrix is the most main joint morphological parameter for determining the joint strength under the high-temperature service condition of the joint. Because the service temperatures of all parts of the active heat protection component are different, the width of the joint surface is required to be large at the part of the component outlet with the height Wen Fuyi; the smaller width of the joint surface can meet the performance requirement of the joint at the low-temperature service position of the inlet of the component. In addition, the rib width of the active heat protection structure is gradually changed along with the flowing direction of the fuel gas. The width dimension of the rib at the inlet end is narrower, the width dimension of the rib at the outlet is increased, and therefore the lap joint is caused to be cracked under the condition of bearing the internal pressure of the same structure, if the effective fusion widths of the joints are consistent, the shearing force of the outlet lap joint is larger, if the effective fusion widths of the lap joint are too small, the joint strength is easily caused to be insufficient, and when the component is high Wen Fuyi, the joint is caused to crack, and the component is scrapped.
Therefore, the current active heat protection component laser welding process is to set welding process parameters aiming at the requirements of the maximum rib width and the maximum service temperature of the component so as to obtain the effective width of the lap joint weld joint surface which can meet the requirements of the maximum joint strength of the weld joint, so that the overall laser welding process is over-high in specification (the appearance of the laser weld joint in an inlet end and a low-temperature assessment area is over-large), the overall laser welding heat input is larger, the overall welding residual stress of the component is over-large in the intensive welding manufacturing process, the deformation and the dimensional instability tendency of the component are serious, the weld joint crack tendency is increased, and the manufacturing quality of the component is seriously affected.
In the active thermal protection structure, the weld joint on each rib is required to be a continuous weld joint, and the existence of break points is not allowed. Therefore, under the condition of the same welding line, how to comprehensively regulate and control the laser welding power, the welding speed and the defocusing quantity parameters according to the size requirements of different temperature intervals and the rib width sizes on the welding surface width of the lap joint, and under the condition of smaller welding heat input, the continuous welding line with the continuously changed welding surface width is obtained, so that the method is a technical key and bottleneck for high-quality completion of the laser welding manufacture of the active heat protection component.
Disclosure of Invention
The invention aims to provide a laser welding process for continuously regulating and controlling effective melting width of a laser lap joint surface of an active heat protection structure, which is suitable for laser welding manufacture of active heat protection components.
A laser welding process for realizing continuous regulation and control of effective melting width of laser lap joint junction surface of active heat protection structure is characterized in that,
The schematic diagram of the active heat protection structure is shown in fig. 1, and mainly comprises a base body (2) and a skin (3) matched with the surface of the base body (2), dense channels (5) are processed on the surface of the base body (2), ribs (1) are arranged between two adjacent channels (5), the base body (2) and the skin (3) are connected through dense welding seams (4), and the welding seams (4) are positioned in the center positions of the ribs (1); wherein: the rib 1 (rib width W), the 2-substrate, the 3-skin, the 4-weld joint, the 5-channel, the 6-penetration H and the 7-bonding surface have effective melting widths W 1, the front view is an active heat protection structure matrix of which half covers the skin, and laser lap welding is performed on the upper half of the cover;
the effective melting width realizes continuous regulation and control: the width of the rib (1) is gradually and continuously widened along the length direction of the rib (1), and the effective melting width of the welding line (4) on the rib (1) is also gradually and continuously widened along with the width of the rib (1);
Aiming at the structural characteristics of gradual change of the width of the active heat protection component and the technological requirements of continuous change of the same welding line on the same bar, the parameters of laser power, welding speed and defocusing amount are required to be comprehensively adjusted for different bar width sizes, and the dynamic change in the welding process of the three is realized, so that the effective melting width of each joint surface of the welding line is well matched with the bar width size at the joint surface. Meanwhile, the welding speed and the defocus amount in the laser welding process parameters are regulated and controlled by inputting a written welding program into a CNC (computer numerical control) system of a machine tool, and the laser power is regulated and controlled by introducing a curve of the laser power changing along with time into the CNC program; thereby obtaining the continuous change of the effective melting width of the same welding seam joint surface.
Firstly, acquiring effective melting width (such as melting width at 1 mm) and basic data set of melting depth of a corresponding welding seam joint surface under each laser welding process parameter through a laser flat scanning pre-experiment; then, according to the change of the rib width size and the effective width size requirement of the joint surface, selecting laser welding process parameters which are well matched with the requirements from a data set, and setting the laser welding process parameters as special node process parameters; according to the rule that the effective melting width of the joint surface increases along with the increase of laser power, increases along with the increase of welding speed and increases along with the increase of positive defocus (on the premise that the depth of a welding line is greater than 1 mm), a buffer node is inserted between every two special nodes so as to improve the continuity of the effective melting width size of the welding line joint surface between the two special nodes; the process parameters of the buffer node refer to the process parameters of the front and rear special nodes, and the laser power or the welding speed or the defocusing amount is singly changed, so that the effective melting width size of the welding joint surface of the buffer node is ensured to be between the effective widths of the joint surfaces of the two special nodes; the buffer node is positioned at the middle position of the welding length of the two special nodes.
The continuous regulation and control method of the technological parameters among the nodes (comprising the special nodes and the buffer nodes) comprises the following steps: inputting the coordinates of Z axes of different nodes in a CNC system of a machine tool, and changing the coordinates of the Z axes along with the movement of a laser head along the welding direction so as to realize continuous regulation and control of the defocus amount; writing a specific instruction language (see embodiment 1) in a CNC system of a machine tool to enable the welding speed between two nodes to change along with the change of the welding position, so as to realize continuous regulation and control of the welding speed between the two nodes; calculating the instant time of each node on a time axis (taking the starting position as the origin of the time axis) of the welding process by using a welding speed regulation instruction language, establishing a time-dependent laser power change curve by matching with the laser power parameters of each node, and leading the time-dependent laser power change curve into a welding subprogram to realize continuous regulation and control of the laser power. Thereby realizing the continuous regulation and control of the effective melting width of the same welding seam joint surface.
In the same lap joint, based on the characteristics of an active heat protection component (the thickness of a skin is 1 mm), the lap joint morphology of which the effective melting width is continuously changed at the joint surface is obtained by comprehensively adjusting parameters of laser power, welding speed and defocus amount and regulating the morphology of the lap joint by utilizing the matching relation between the laser input line energy and the light spot size.
Aiming at different service temperature intervals and different position rib width sizes of the active heat protection component, a CNC system of a machine tool is utilized, a welding program is written, and related instruction language is utilized to realize continuous regulation and control of laser power, welding speed and defocusing amount, so that effective width of a bonding surface is continuously adjustable.
The laser lap joint surface effective melting width continuous regulation laser welding process is characterized in that: aiming at the lap joint of the skin of 1mm, the adjustment range of each parameter is as follows: the laser power is 1200-3000W, the welding speed is 2-6 m/min, and the defocusing amount is 0- +8mm.
The laser lap joint surface effective melting width continuous regulation laser welding process is characterized in that: lasers that may be used are CO 2 lasers, fiber lasers, and semiconductor lasers.
The invention has the following beneficial effects: by combining and regulating welding power, welding speed and defocusing quantity parameters, continuous change of the fusion width of the joint surface of the lap joint can be realized, welding heat input and welding seam area are reduced on the basis that the quality of the joint manufactured by laser welding of an active heat protection component meets high-temperature heat intensity, and further, component residual stress is greatly reduced, welding seam crack tendency, welding deformation, size instability and the like are reduced, and the laser welding manufacturing quality of the active heat protection component is improved.
Drawings
Fig. 1 is a schematic view of an active thermal protection structure with gradual rib width change according to embodiment 1;
FIG. 2 is a graph showing the specific laser welding process parameters used in example 1;
FIG. 3 shows the macroscopic morphology of the different locations obtained in example 1.
Example 1
According to the method, an optical fiber laser is adopted, and the optimization matching design of laser power, welding speed and defocusing amount is carried out according to the requirements of an active heat protection structure with the thickness of 1mm on the fusion width and the fusion depth of a lap joint weld joint surface, so that the continuous regulation and control of the fusion width of the joint surface are realized. Firstly, based on the requirements of different thermal service parts and rib widths of the active thermal protection structure on the width dimension of the bonding surface of the lap joint weld, obtaining relevant welding process parameter sets of effective widths of different bonding surfaces through a laser flat-plate scanning pre-test. As shown in Table 1, where P is the laser power, v is the welding speed, Δf is the defocus amount, W 1 is the weld bead fusion width at 1mm, and H is the weld bead penetration. Wherein, the effective melting widths of the welding seam bonding surfaces with matched rib widths at special positions (low temperature Duan Kaitou, medium temperature Duan Kaitou, medium temperature Duan Jiewei and high temperature end of sections) under different service temperatures are about 0.45mm, 0.55mm, 0.65mm and 0.75mm. In combination with the experimental data of table 1,4 technological parameters were selected for which the effective melting widths of the bonding surfaces meet the requirements. The laser power, the welding speed and the defocus amount are 1400W,4m/min and 0mm respectively; 2200W,4m/min, +4mm;1800W,2m/min, +6mm;2000W,2m/min, +8mm, set to 4 special nodes.
Based on the consideration of the effective width controllability of the joint surface of the two nodes on the welding length, a buffer node is inserted into the middle position of each two special nodes so as to improve the continuity of the effective width dimension of the welding joint surface between the two nodes. The process parameters of the buffer node are 1400W,5m/min and 0mm respectively; 1800W,4m/min, +2mm;1800W,3m/min, +6mm;1900W,2m/min, +8mm. Wherein, in order to ensure that the effective junction surface melting width of about 0.45mm is stably realized by the first special node, a buffer node is added in front of the node, and the technological parameters are 1400W,5m/min and 0mm. Thus, a variation combination of 8 nodes is formed, as shown in table 2.
According to the characteristic that the width of the active cooling component at low temperature Duan Zhigao and Duan Jin gradually increases from small size, the effective width of the joint surface of four special positions of the whole welding seam is designed as follows: low temperature Duan Kaitou, effective melting width of the joint surface is about 0.5mm; medium temperature Duan Kaitou, effective melting width of the joint surface is about 0.55mm; medium temperature Duan Jiewei, effective melting width of the joint surface is about 0.65mm; at the end of the high temperature section, the effective melting width of the joint surface is about 0.75mm, and the depth of each welding line is greater than 1.5mm.
Accordingly, the process parameter change curve (shown in fig. 2) of the embodiment is designed, and the laser power, the welding rate and the defocus amount are respectively and continuously regulated and controlled.
To realize real-time regulation and control of laser power, welding speed and defocus in the welding process, the following method is adopted to regulate the three parameters. The continuous regulation and control mode of the welding speed and the defocusing amount is to write a welding program by using a CNC system of a machine tool and realize continuous change of the defocusing amount by using Z coordinate change of the machine tool in a code.
The defocus amount continuous regulation instruction is as follows:
G01X100Z2F4000
G01X150Z4F4000
In this example, the positive X direction is the welding direction, the positive Z direction is the positive defocus direction, and the defocus 0 is set to Z0. In the instruction language, G01 represents that the welding head moves in a linear direction; x100 represents the movement of the welding head to a position where the length of the welding seam is 100 mm; z2 represents that the welding head moves the focal point of the laser beam to a distance of 2mm from the surface of the workpiece at a speed of 4 m/min; f4000 represents a movement speed of the welding head of 4000mm/min. The two instructions indicate that the laser head continuously increases the defocus amount from +2mm to +4mm within 50mm of the welding direction under the movement speed of 4000mm/min, so that the continuous regulation and control of the defocus amount within 50mm is realized.
Continuous regulation and control of welding speed are realized by using the following specific instruction language:
FCTDEF(Polynomial_No.,LLIMIT,ULIMIT,a0,a1,a2,a3)
ID＝1DO SYNFCT(Polynomial_No.,$AC_OVR,$AC_DTBW)
Wherein FCTDEF is a polynomial defining instruction, polynomial _no. means polynomial number, LLIMIT means lower limit of function value, ULIMIT means upper limit of function value, and a 0～a3 means polynomial coefficient. The use FCTDEF instruction may define a polynomial of order 3 in the form y=a 0+α1x+α2x2+a3x3, which is used by the computing function SYNFCT. Id=1 means that the synchronization action is valid in the following modality procedure section, i.e. FCTDEF is valid only in SYNFCT. SYNFCT is a synchronous function instruction, polynomial _no. means that the number of the polynomial is the same as the number in FCTDEF, ac_ovr means that the system speed multiplying power is modified, and ac_ DTBW means that the distance after the program starts to run is variable. SYNFCT instruction inputs $AC_ DTBW (i.e., x mm in polynomial) into the function defined by FCTDEF, then outputs $AC_OVR, and there are upper and lower limits LLIMIT and ULIMIT for the output $AC_OVR. The design FCTDEF instruction in this embodiment is a first order polynomial, so Polynomial _no. 1, a 2 and a 3 are both 0; in this embodiment, the range of the function value in the design FCTDEF is 0 to 100, so the instruction language used in this embodiment is:
FCTDEF(1,0,100,a0,a1)
ID＝1DO SYNFCT(1,$AC_OVR,$AC_DTBW)
The relation between the movement speed of the welding head and the distance variable is shown as a formula (1):
v＝v0y％＝v0(a0+a1x)％ (1)
Wherein v is the target speed, v 0 is the initial speed unit, mm/min, x is the distance variable of the instruction, in this example, the distance variable between two nodes, and a 0,a1 is the freely set regulation and control coefficient.
The final effect of the instruction in the embodiment is that the welding speed is continuously changed along with the change of the welding path in the process that the laser head moves from one node to the next adjacent node, so that the continuous regulation and control of the welding speed are realized.
To obtain a corresponding curve of laser power in the same time and realize continuous regulation and control of the laser power in the welding process, specific welding time points at all nodes must be obtained first. The relation between the instantaneous welding speed, the distance and the time in the welding process is shown in a formula (2). And (3) carrying out integral (3) by the formula (1), and obtaining the welding time of two adjacent nodes according to the welding distance of 50mm between the two adjacent nodes, so that the specific welding time point when the laser head moves to each node can be calculated.
The continuous variation of the power of this example is achieved using a method of laser power programming. By using the calculated time of the specific distance, the power of each specific distance time is designed by combining the laser powers of the 8 selected nodes, the change rule of each power is in direct proportion to the welding time, so as to form a laser power curve (in a linear function relationship with the welding time), and the laser power curve is stored as a subprogram. In the welding procedure, the designed laser power curve is led into the laser control system by calling the subprogram, so as to realize the continuous change of the laser power.
Through the continuous regulation and control method of the defocusing amount, the welding speed and the laser power, a laser welding process parameter change curve of a welding seam with the length of 350mm as shown in fig. 2 is finally obtained, and the step length between each two nodes is set to be 50mm.
TABLE 1 weld pre-test process parameters and weld morphology and size
Table 2 welding Process parameters and specific control parameters at different positions of Components
The material used in this example was GH3128 metal sheet, 4mm thick and 400mm long, and acetone was used to remove oil from the surface of the work piece to be welded prior to welding. And selecting relevant positions after welding to prepare metallographic samples, corroding the welding seams by adopting aqua regia (6mLHCl+2mLHNO 3), and cleaning the welding seams by using alcohol. And observing the shape of the welding seam by adopting an optical microscope (OLYMPUS GX 51), calculating the width of the welding seam at the position 1mm away from the surface of the welding seam, and representing the effective melting width of the bonding surface of the lap welding seam when the thickness of the skin is 1mm, so as to analyze the beneficial effects of the invention.
The surface morphology of the whole welding seam and the cross-section morphology of the welding seam at different positions (shown in figure 3) are obtained after welding, the morphology data of the welding seam at each position are shown in table 3, wherein W represents the corresponding rib width dimension at the position, H represents the penetration depth, and S represents the area of the welding seam. Wherein, the starting point of the welding seam is taken as the origin, the welding seam with the W 1 of 0.41mm is obtained at the position of the welding seam with the thickness of 43mm, the penetration is 1.633mm, and the area of the welding seam is 0.826mm 2; a welding line with W 1 of 0.579mm, penetration of 2.129mm and welding line area of 1.333mm 2 is obtained at the position of 145 mm; a welding line with W 1 of 0.719mm, penetration of 2.357mm and welding line area of 1.765mm 2 is obtained at the position of 247mm of the welding line; a welding line with W 1 of 0.8mm is obtained at the position of 331mm of the welding line, the penetration is 2.354mm, and the welding line area is 1.975mm 2.
From the shape of the weld cross section, for example 1, the melting width of the part 1mm away from the upper surface of the workpiece is continuously changed from 0.41mm to 0.8mm, the change amount is nearly doubled, and the melting depth is stable and the change range is smaller. The embodiment shows that the effective continuous change of the width of the high-temperature alloy lap joint weld joint surface can be ensured at different rib width positions by comprehensively regulating and controlling the matching relation of the laser power, the welding speed and the defocusing amount, and the fluctuation of the weld penetration is small.
TABLE 3 weld morphology data at different locations
The present invention is not limited to the above-mentioned embodiments, and any changes or substitutions that can be easily understood by those skilled in the art within the technical scope of the present invention are intended to be included in the scope of the present invention. Therefore, the protection scope of the present invention should be subject to the protection scope of the claims.
Claims (6)
1. The laser welding process is characterized in that the active thermal protection structure mainly comprises a substrate (2) and a skin (3) matched with the surface of the substrate (2), dense channels (5) are processed on the surface of the substrate (2), ribs (1) are arranged between two adjacent channels (5), the substrate (2) and the skin (3) are connected through dense welding seams (4), and the welding seams (4) are positioned in the center of the ribs (1);
the effective melting width realizes continuous regulation and control: the width of the rib (1) is gradually and continuously widened along the length direction of the rib (1), and the effective melting width of the welding line (4) on the rib (1) is also gradually and continuously widened along with the width of the rib (1);
aiming at the structural characteristics of gradual change of the width of the active heat protection component and the technological requirements of continuous change of the same welding line on the same bar, the parameters of laser power, welding speed and defocusing amount are required to be comprehensively adjusted for different bar width sizes, so that the dynamic change in the welding process of the three is realized, and the effective melting width of each joint surface of the welding line is well matched with the bar width size at the joint surface;
The method specifically comprises the following steps:
Firstly, acquiring basic data sets of effective melting width and melting depth of a corresponding welding seam joint surface under each laser welding process parameter through a laser flat scanning pre-experiment; then, according to the change of the rib width size and the effective width size requirement of the joint surface, selecting laser welding process parameters which are well matched with the requirements from a data set, and setting the laser welding process parameters as special node process parameters; according to the rule that the effective melting width of the joint surface increases along with the increase of laser power, increases along with the increase of welding speed and increases along with the increase of positive defocus, a buffer node is inserted between every two special nodes so as to improve the continuity of the effective melting width size of the welding joint surface between the two special nodes; the process parameters of the buffer node refer to the process parameters of the front and rear special nodes, and the laser power or the welding speed or the defocusing amount is singly changed, so that the effective melting width size of the welding joint surface of the buffer node is ensured to be between the effective widths of the joint surfaces of the two special nodes; the buffer node is positioned in the middle of the welding length of the two special nodes;
The continuous regulation and control method for the technological parameters among the nodes including the special nodes and the buffer nodes comprises the following steps: inputting the coordinates of Z axes of different nodes in a CNC system of a machine tool, and changing the coordinates of the Z axes along with the movement of a laser head along the welding direction so as to realize continuous regulation and control of the defocus amount; writing a specific instruction in a CNC system of the machine tool to enable the welding speed between two nodes to change along with the change of the welding position, so as to realize continuous regulation and control of the welding speed between the two nodes; calculating the instant moment of each node on a welding process time axis by using a welding speed regulation instruction language, establishing a time-dependent laser power change curve by matching with the laser power parameters of each node, and leading the time-dependent laser power change curve into a welding subprogram to realize continuous regulation and control of the laser power; thereby realizing the continuous regulation and control of the effective melting width of the same welding seam joint surface.
2. The process according to claim 1, wherein the regulation of the welding speed and the defocus in the laser welding process parameters is achieved by inputting a written welding program into the CNC system of the machine tool, and the regulation of the laser power is achieved by introducing a curve of the laser power over time into the CNC program; thereby obtaining the continuous change of the effective melting width of the same welding seam joint surface.
3. The process according to claim 1, wherein in the same lap joint, based on the characteristics of the active heat protection component, the lap joint morphology of which the effective melting width of the joint surface is continuously changed is obtained by comprehensively adjusting parameters of laser power, welding speed and defocus and regulating the morphology of the lap joint by utilizing the matching relation of laser input line energy and light spot size.
4. The process according to claim 1, wherein for different service temperature intervals and different position rib width sizes of the active heat protection component, a CNC system of a machine tool is utilized, a welding program is written, and related instruction language is utilized to realize continuous regulation and control of laser power, welding speed and defocusing amount, so that effective continuous adjustment of the width of a bonding surface is realized.
5. The process of claim 1 wherein said laser lap joint interface effective melt width is continuously modulated for a laser welding process, wherein: aiming at the lap joint of the skin of 1mm, the adjustment range of each parameter is as follows: the laser power is 1200-3000W, the welding speed is 2-6 m/min, and the defocusing amount is 0- +8mm.
6. The process according to claim 1, wherein the laser used is a CO 2 laser, a fiber laser or a semiconductor laser.
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